Phosphor powder, light-emitting device, image display device, and illumination device

ABSTRACT

A phosphor powder including phosphor particles which are a phosphor represented by a general formula Mx(Si, Al)2(N, O)3±y (where M is Li and one or more alkaline earth metal elements and 0.52≤x≤0.9 and 0.06≤y≤0.36 are satisfied) and in which a part of M is substituted with a Ce element, wherein a Si/Al atomic ratio is equal to or more than 1.5 and equal to or less than 6, an O/N atomic ratio is equal to or more than 0 and equal to or less than 0.1, 5 to 50 mol % of M is Li, and 0.5 to 10 mol % of M is Ce, and a total content of a Cr element, a Fe element, and a Ni element in the phosphor powder is equal to or less than 20.0 ppm.

TECHNICAL FIELD

The present invention relates to a phosphor powder, a light-emittingdevice, an image display device, and an illumination device.

BACKGROUND ART

Phosphors are commonly used to manufacture white LED (Light EmittingDiode). That is, a phosphor is used as a wavelength conversion materialfor obtaining white light from blue light emitted from a blue LED.

With the spread of white LED for illumination and studies regardingapplication of the white LED to image display devices, phosphors capableof converting blue light into light having longer wavelengths arecontinuously being developed.

An aspect of improving a phosphor is to modify a chemical composition ofthe phosphor.

For example, Patent Document 1 discloses a phosphor which is representedby a general formula M_(x)(Si, Al)₂(N, O)_(3±y) (where M is Li and oneor more alkaline earth metal elements and 0.52≤x≤0.9 and 0.06≤y≤0.23 aresatisfied) and in which a part of M is substituted with a Ce element, inwhich the phosphor which is a Si/Al atomic ratio is equal to or morethan 1.5 and equal to or less than 6, an O/N atomic ratio is equal to ormore than 0 and equal to or less than 0.1, 5 to 50 mol % of M is Li, and0.5 to 10 mol % of M is Ce.

RELATED DOCUMENT Patent Document

-   Patent Document 1: Japanese Patent No. 5969391

SUMMARY OF THE INVENTION Technical Problem

As a finding of the present inventor, a phosphor disclosed in PatentDocument 1 has room for improvement in terms of a fluorescence peakintensity when the phosphor is irradiated with blue light.

The present inventor herein conducted studies to provide a phosphorpowder having a great fluorescence peak intensity when a phosphor isirradiated with blue light, as one of the object.

Solution to Problem

The present inventors completed the invention provided below as a resultof the studies.

According to the present invention, there is provided a phosphor powderincluding phosphor particles which are a phosphor represented by ageneral formula M_(x)(Si, Al)₂(N, O)_(3±y)(where M is Li and one or morealkaline earth metal elements and 0.52≤x≤0.9 and 0.06≤y≤0.36 aresatisfied) and in which a part of M is substituted with a Ce element,wherein a Si/Al atomic ratio is equal to or more than 1.5 and equal toor less than 6, an O/N atomic ratio is equal to or more than 0 and equalto or less than 0.1, 5 to 50 mol % of M is Li, and 0.5 to 10 mol % of Mis Ce, and a total content of a Cr element, a Fe element, and a Nielement in the phosphor powder is equal to or less than 20 ppm.

In addition, according to the present invention, there is provided alight-emitting device including the phosphor powder described above anda light emitting source.

In addition, according to the present invention, there is provided animage display device including the light-emitting device describedabove.

In addition, according to the present invention, there is provided anillumination device including the light-emitting device described above.

Advantageous Effects of Invention

The phosphor powder of the present invention can provide a phosphorpowder having a high fluorescence peak intensity when the phosphor isirradiated with blue light.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic cross-sectional view showing an example of astructure of a light-emitting device.

FIG. 2 is an XRD pattern obtained by powder X-ray diffraction (XRD)measurement of a phosphor of Example 1.

DESCRIPTION OF EMBODIMENTS

Hereinafter, an embodiment of the present invention will be described indetail while referring to drawings.

In the drawings, similar components are designated by the same referencenumerals, and the description thereof will not be repeated.

The drawings are for explanation purposes only. A shape or a dimensionalratio of each member in the drawing does not necessarily correspond toan actual article.

In the present specification, the notation “X to Y” in the descriptionof the numerical range indicates X or more and Y or less unlessotherwise specified. For example, “1 to 5% by mass” means “equal to ormore than 1% by mass and equal to or less than 5% by mass”.

<Phosphor Powder>

A phosphor powder of the present embodiment includes phosphor particlesrepresented by a general formula M_(x)(Si, Al)₂(N, O)_(3±y). In thisgeneral formula, M represents Li and one or more alkaline earth metalelements, and 0.52≤x≤0.9 and 0.06≤y≤0.36 are satisfied. In addition, apart of M is substituted with a Ce element, a Si/Al atomic ratio isequal to or more than 1.5 and equal to or less than 6, an O/N atomicratio is equal to or more than 0 and equal to or less than 0.1, 5 to 50mol % of M % is Li, and 0.5 to 10 mol % of M is Ce.

A total content of a Cr element, a Fe element, and a Ni element in thephosphor powder is equal to or less than 20 ppm.

According to the findings of the present inventor, it was found thatfluorescence properties of the phosphor can be evaluated by usingcontents of a plurality of elements included in the phosphor powder intrace amounts as an index. As a result of intensive studies based onthis finding, it was found that, the fluorescence properties can bestably evaluated by using the total content of the Cr element, the Feelement, and the Ni element as an index, and a phosphor powder having ahigh fluorescence peak intensity when the phosphor is irradiated withblue light can be realized by setting a total value of the content,which is the index, to be equal to or less than the upper limit value.

The upper limit of the total content of the Cr element, the Fe element,and the Ni element is equal to or less than 20 ppm, preferably equal toor less than 15 ppm, and more preferably equal to or less than 10 ppm.Accordingly, it is possible to realize a phosphor powder having a highfluorescence peak intensity when the phosphor is irradiated with bluelight.

The lower limit of the total content is not particularly limited, andmay be equal to or more than 0 ppm or equal to or more than 0.01 ppm.

An upper limit of the content of the Cr element is equal to or less than10 ppm, preferably equal to or less than 5 ppm, and more preferablyequal to or less than 3 ppm. Accordingly, it is possible to realize aphosphor powder having high internal quantum efficiency and improvedblue light conversion efficiency.

A lower limit of the content of the Cr element is not particularlylimited, and may be equal to or more than 0 ppm or equal to or more than0.01 ppm.

An upper limit of the content of the Fe element is equal to or less than20 ppm, preferably equal to or less than 15 ppm, and more preferablyequal to or less than 10 ppm. Accordingly, it is possible to realize aphosphor powder having high internal quantum efficiency and improvedblue light conversion efficiency.

A lower limit of the content of the Fe element is not particularlylimited, and may be equal to or more than 0 ppm or equal to or more than0.01 ppm.

An upper limit of the content of the Ni element is equal to or less than10 ppm, preferably equal to or less than 5 ppm, and more preferablyequal to or less than 3 ppm. Accordingly, it is possible to realize aphosphor powder having high internal quantum efficiency and improvedblue light conversion efficiency.

A lower limit of the content of the Ni element is not particularlylimited, and may be equal to or more than 0 ppm or equal to or more than0.01 ppm.

An upper limit of the content of the Ti element is equal to or less than10 ppm, preferably equal to or less than 5 ppm, and more preferablyequal to or less than 3 ppm. Accordingly, it is possible to realize aphosphor powder having high internal quantum efficiency and improvedblue light conversion efficiency.

A lower limit of the content of the Ti element is not particularlylimited, and may be equal to or more than 0 ppm or equal to or more than0.01 ppm.

The phosphor powder is dissolved with a mixed acid of hydrofluoric acidand nitric acid by a pressure acid decomposition method, and then, theCr element, the Fe element, the Ni element, and the Ti element can bemeasured by an ICP emission spectrometer.

A content of 0 ppm means a detection limit of a measuring device.

In the present embodiment, the phosphor powder, in which the contents ofthe Cr element, the Fe element, the Ni element, and the Ti elementsatisfy desired ranges, can be produced by selecting suitable productionmethod⋅production conditions, in addition to usage of suitablematerials. The “suitable production method⋅production conditions” is,for example, one or two or more of (i) performing a suitableclassification treatment (preferably sedimentation classification) onthe phosphor powder, (ii) devising an acid treatment, and the like. Theproduction method⋅production conditions will be described later in moredetail.

The description of the phosphor powder of the present embodiment will becontinued.

(Crystal Structure, Chemical Composition, and the like) A skeletonstructure of a phosphor crystal is composed of (Si, Al)—(N, O)₄ regulartetrahedrons bonded together, and an M element is located in theinterstices. A composition of the general formula described above issatisfied in a wide range in which electrical neutrality is maintainedby all the parameters of a valence and an amount of the M element, theSi/Al ratio, and the N/O ratio. As a representative phosphor representedby the general formula described above, there is CaAlSiN₃ where the Melement is Ca, x=1, Si/Al=1, and O/N=0. When a part of Ca in CaAlSiN₃ issubstituted with Eu, it becomes a red phosphor, and when a part thereofis substituted with Ce, it becomes a yellow-orange phosphor.

The crystal structure of the phosphor particles included in the phosphorpowder of the present embodiment is usually based on CaAlSiN₃ crystals.One of features of the phosphor particles is that constituent elementsand a composition are greatly changed so that an extremely high lightemission efficiency can be obtained even with Ce activation.

In the general formula described above, the M element is a combinationof a Li element and an alkaline earth metal element, and a part thereofis substituted with a Ce element serving as a light emission center. Byusing the Li element, an average valence of the M element can be widelycontrolled by combining with a divalent alkaline earth element and atrivalent Ce element. In addition, since an ionic radius of Li⁺ isextremely small, a crystal size can be changed greatly depending on theamount thereof, and various fluorescence emissions can be obtained.

A coefficient x of the M element in the general formula described aboveis equal to or more than 0.52 and equal to or less than 0.9, preferablyequal to or more than 0.6 and equal to or less than 0.9, and morepreferably equal to or more than 0.7 and equal to or less than 0.9. Whenthe coefficient x exceeds 0.9, that is, when it approaches the CaAlSiN₃crystal, the fluorescence intensity tends to decrease. When thecoefficient x is smaller than 0.52, a large amount of a heterogeneousphase other than the desired crystal phase is generated, and thus, thefluorescence intensity tends to significantly decrease.

In the present embodiment, when the electrical neutrality is maintainedby the average valence or the amount of the M element, the Si/Al ratio,and the O/N ratio and there is no defects or the like in a singlecrystal, y=0. However, when considering the composition of the entirephosphor, a secondary crystal phase or an amorphous phase exists, andeven when considering the crystal itself, a charge balance may be lostdue to crystal defects. In the present embodiment, from a viewpoint ofincreasing the fluorescence intensity, y is preferably equal to or morethan 0.06 and equal to or less than 0.36, more preferably equal to ormore than 0.1 and equal to or less than 0.35, and even more preferablyequal to or more than 0.06 and equal to or less than 0.23.

In the present embodiment, the O/N atomic ratio (a molar ratio) is equalto or more than 0 and equal to or less than 0.1, preferably equal to ormore than 0.01 and equal to or less than 0.08, and more preferably equalto or more than 0.02 and equal to or less than 0.07. When the O/N atomicratio is too large, the amount of the heterogeneous phases generatedincreases, the light emission efficiency decreases, a covalent bondingproperty of the crystal tends to decrease, and a deterioration of atemperature property (a decrease in luminance at a high temperature)tends to be caused.

The Si/Al atomic ratio (the molar ratio) is usually inevitablydetermined when the average valence or the amount of the M element andthe O/N atomic ratio are set in predetermined ranges. The Si/Al atomicratio is equal to or more than 1.5 and equal to or less than 6,preferably equal to or more than 2 and equal to or less than 4, and morepreferably equal to or more than 2.5 and equal to or less than 4.

A Li content in the phosphor particles is 5 to 50 mol %, preferably 15to 45 mol %, and more preferably 25 to 45 mol % of the M element. Aneffect of Li is likely to be exhibited, when the Li content is equal toor more than 5 mol %, but, if the Li content exceeds 50 mol %, thedesired crystal structure of the phosphor cannot be maintained, theheterogeneous phases are generated, and the light emission efficiency islikely to decrease.

Just to be sure, the “Li content” is the Li content in the finallyobtained phosphor powder, not the amount based on a raw materialmixture. The Li compound used as a raw material has a high vaporpressure and is easily volatilized, and a considerable amountvolatilizes when an attempt is made to synthesize a nitride⋅oxynitrideat a high temperature. That is, the amount of Li based on the rawmaterial mixture is largely different from the content in the finalproduct, and thus, does not mean the Li content in the phosphor.

When the content of Ce, which is the light emission center of thephosphor particles, is too small, the contribution to the light emissiontends to decrease. When the content thereof is too great, concentrationquenching of the phosphor due to energy transfer between Ce³⁺ tends tooccur. Therefore, the content of Ce is 0.5 to 10 mol % and preferably0.5 to 5 mol % of the M element.

The alkaline earth metal element used as the M element in the generalformula described above may be any element, but, in a case where Ca isused, a high fluorescence intensity is obtained and the crystalstructure is stabilized in a wide composition range. Therefore, the Melement is preferably Ca. A combination of a plurality of alkaline earthmetal elements may be used, and for example, a part of the Ca elementmay be substituted with a Sr element.

The crystal structure of the phosphor particles is orthorhombic, and mayhave the same structure as the CaAlSiN₃ crystal described above. Latticeconstants of the CaAlSiN₃ crystal are, as an example, a=0.9800 nm,b=0.5649 nm and c=0.5062 nm. In the present embodiment, the latticeconstants are usually a=0.9350 to 0.9650 nm, b=0.5500 to 0.5700 nm, andc=0.4800 to 0.5000 nm, and all of the values are small values comparedto the CaAlSiN₃ crystal. The ranges of the lattice constants reflect theconstituent elements and the composition described above.

A crystal phase present in the phosphor particles is preferably thesingle crystal phase described above. However, the phosphor particlesmay include a heterogeneous phase as long as the fluorescence propertiesare not significantly affected. Examples of the heterogeneous phasehaving a low effect on the fluorescence properties in a case of bluelight excitation are α-sialon, AlN, LiSi₂N₃, and LiAlSi₂N₄. The amountof the heterogeneous phase is preferably an amount such that adiffraction line intensity of other crystal phases with respect to astrongest diffraction line intensity of the crystal phase is equal to orless than 40% when evaluated by a powder X-ray diffraction method.

The phosphor powder of the present embodiment is excited by light havinga wide wavelength range from ultraviolet to visible light. For example,in a case where blue light having a wavelength of 455 nm is emitted,broad fluorescence emission with a half width of the fluorescencespectrum equal to or more than 125 nm may be exhibited with orange lighthaving a peak wavelength of 570 to 610 nm. Such a phosphor powder issuitable as a phosphor for wide-range light-emitting devices. Inaddition, the phosphor powder of the present embodiment has excellentheat resistance and chemical stability and a property, in which aluminance decrease due to an increase in temperature is small, in thesame manner as a nitride⋅oxynitride-based phosphor of the related artrepresented by CaAlSiN₃. Such properties are particularly suitable forapplications requiring durability.

(Particle Size Distribution) By suitably designing a particle sizedistribution of the phosphor powder of the present embodiment, quantumefficiency may be further increased or the balance of variousperformances may be improved.

Specifically, a volume-based cumulative 50% size D50 (a so-called mediansize) of the phosphor powder of the present embodiment measured by alaser diffraction scattering method is preferably equal to or more than8 μm and equal to or less than 25 μm, more preferably equal to or morethan 10 μm and equal to or less than 20 μm, and more preferably equal toor more than 12 μm and equal to or less than 20 μm.

From another viewpoint, a volume-based cumulative 10% size D₁₀ of thephosphor powder of the present embodiment measured by the laserdiffraction scattering method is preferably equal to or more than 2 μmand equal to or less than 15 μm and more preferably equal to or morethan 5 μm and equal to or less than 12 μm. A comparatively large valueof D₁₀ corresponds to a comparatively small amount of a fine powder(excessively fine phosphor particles in which the conversion efficiencyof the blue light tends to decrease) in the phosphor powder. Therefore,the conversion efficiency of the blue light tends to increase, when D₁₀is a relatively large value.

From another viewpoint, a volume-based cumulative 90% size D₉₀ of thephosphor powder of the present embodiment measured by the laserdiffraction scattering method is preferably equal to or more than 15 μmand equal to or less than 50 μm and more preferably equal to or morethan 18 μm and equal to or less than 40 μm. D₉₀ that is not excessivelylarge corresponds to a small amount of coarse particles in the phosphorpowder. The phosphor powder having D₉₀ that is not excessively large iseffective in reducing the chromaticity variation of the light-emittingdevice.

In addition, in general, as a particle size of particles included in thepowder increases, the effect of light scattering decreases and diffusereflectance tends to decrease. In other words, a size of the particleand the diffuse reflectance are in a relationship of trade-off. However,although a preferred particle size (D₅₀ or the like) of the phosphorpowder of the present embodiment is comparatively large, the diffusereflectance of the phosphor powder of the present embodiment tends to becomparatively large.

(Production Method)

The phosphor powder of the present embodiment is preferably produced bya series of steps including the following (1) to (4), a series of stepsincluding (1) to (3) and (5), or a series of steps including (1) to (5).From a viewpoint of suitably adjusting (D₉₀−D₁₀)/D₅₀, a production stepof the phosphor powder preferably includes a (5) classification step(preferably a sedimentation classification).

-   -   (1) Preparation step of raw material mixed powder    -   (2) Firing step    -   (3) Pulverization step of fired product    -   (4) Acid treatment step    -   (5) Classification step (preferably sedimentation        classification)

(1) to (5) will be specifically described below.

(1) Preparation Step of Raw Material Mixed Powder

In the preparation step of raw material mixed powder, a raw materialmixed powder is normally obtained by mixing suitable raw materialpowders.

As the raw material powder, nitrides of constituent elements such assilicon nitride, aluminum nitride, lithium nitride, cerium nitride, andnitrides of alkaline earth elements (for example, calcium nitride) arepreferably used. In general, a nitride powder is unstable in air, andthe particle surface is covered with an oxide layer, and as a result,even in a case where the nitride raw material is used, a certain amountof oxide is contained in the raw material. In a case of controlling theO/N ratio of the phosphor, when these are considered and the amount ofoxygen is insufficient, a portion of the nitride may be an oxide(including a compound that becomes an oxide by heat treatment). Examplesof oxide can include cerium oxide and the like.

Among the raw material powders, a lithium compound is remarkablyvolatilized by heating, and most of them may be volatilized depending ona firing condition. Therefore, it is preferable to determine the amountof the lithium compound to be blended in consideration of thevolatilization amount during a firing process according to the firingcondition.

Among the nitride raw material powders, lithium nitride, cerium nitride,and nitride of the alkaline earth element react violently with moisturein the air. Therefore, it is preferable to carry out these handlings ina glove box substituted with an inert atmosphere.

From a viewpoint of work efficiency, it is preferable that, (i) first,predetermined amounts of the raw material powders of silicon nitride,aluminum nitride, and various oxides that can be handled in the air areweighed and thoroughly mixed in the air in advance to prepare a premixedpowder, (ii) then, the premixed powder is mixed with a substance such aslithium nitride that reacts easily with moisture in a glove box toprepare a raw material mixed powder.

(2) Firing Step

In the firing step, the raw material mixed powder prepared in the (1)preparation step of raw material mixed powder is filled in a suitablecontainer and heated using a firing furnace or the like.

A firing temperature is preferably 1600° C. to 2000° C. and morepreferably 1700° C. to 1900° C., from viewpoints of sufficientlyproceeding the reaction and suppressing the volatilization of lithium.

A firing time is preferably 2 to 24 hours and more preferably 4 to 16hours, from viewpoints of sufficiently proceeding the reaction andsuppressing the volatilization of lithium.

The firing step is preferably performed in a nitrogen atmosphere. Inaddition, it is preferable to appropriately adjust a pressure of thefiring atmosphere. Specifically, the pressure of the firing atmosphereis preferably equal to or more than 0.5 MPa·G. Particularly, in a casewhere the firing temperature is equal to or higher than 1800° C., thephosphor tends to be easily decomposed, but the high pressure of thefiring atmosphere can suppress the decomposition of the phosphor.

Incidentally, considering industrial productivity, the pressure of thefiring atmosphere is preferably less than 1 MPa·G.

It is preferable that the container filled with the raw material mixedpowder is formed of a material that is stable in a high-temperaturenitrogen atmosphere and does not react with the raw material mixedpowder or a reaction product thereof. A material of the container ispreferably boron nitride.

(3) Pulverization Step of Fired Product

Since a fired product obtained in (2) is usually in the form of a block,it is preferable to pulverize it to a somewhat small size by applying amechanical force.

In the pulverization, various devices such as a crusher, a mortar, aball mill, a vibration mill, a jet mill, and a stamp mill can be used.Two or more of these devices may be combined for the pulverization. Inexamples which will be described later, first, a stamp mill is used toobtain a coarsely pulverized product of the fired product, and then thecoarsely pulverized product is further finely pulverized using a jetmill. One or two or more of D₁₀, D₅₀, D₉₀, and (D₉₀−D₁₀)/D₅₀ can also beadjusted by suitably controlling a pulverization condition.

(4) Acid Treatment Step

In the acid treatment step, for example, the pulverized product obtainedin (3) above is immersed in an acidic aqueous solution. Although thedetails are not clear, it is considered that the acid treatment removesor reduces “heterogeneous phases” in the phosphor that do not contributeto the light emission or that reduce the light emission efficiency.

Examples of the acidic aqueous solution include an acidic aqueoussolution containing one acid selected from acids such as hydrofluoricacid, nitric acid, and hydrochloric acid, and a mixed acid aqueoussolution obtained by mixing two or more of the above acids. The acid ispreferably nitric acid or hydrochloric acid and more preferablyhydrochloric acid.

A concentration of the acidic aqueous solution is suitably set accordingto strength of the acid used, and is, for example, 0.5 to 50% by mass,preferably 1 to 30% by mass, and more preferably 1 to 10% by mass.

A temperature in a case of performing the acid treatment is preferablyequal to or higher than 25° C. and equal to or lower than 90° C. andmore preferably equal to or higher than 60° C. and equal to or lowerthan 90° C. By performing the treatment at a comparatively hightemperature, it is easy to remove the heterogeneous phase.

A time of the acid treatment (an immersion time) is preferably equal toor more than 15 minutes and equal to or less than 80 minutes and morepreferably equal to or more than 15 minutes and equal to or less than 60minutes.

After the acid treatment, it is preferable to sufficiently wash thephosphor powder with water and dry it.

(5) Classification Step

In order to reduce the amount of fine powder (extremely fine phosphorparticles that tend to deteriorate the conversion efficiency of bluelight) in the powder, it is preferable to perform a suitableclassification treatment. In order to effectively remove the finepowder, a classification method is preferably sedimentationclassification as described below.

First, the powder obtained in (3) the pulverization step of the firedproduct or the powder obtained through (4) the acid treatment step isdispersed in a suitable liquid, for example, an aqueous solution ofsodium hexametaphosphate in a container to obtain a dispersion.

Next, the dispersion is allowed to stand for a predetermined period oftime to precipitate powders having comparatively large particle sizesamong the powder in the dispersion.

After that, a supernatant is discharged.

Then, the operations of newly putting the aqueous solution of sodiumhexametaphosphate into the container in which the sediment remains,dispersing the powder, allowing the mixture to stand, and dischargingthe supernatant are repeated multiple times. The “multiple times” ispreferably equal to or more than 5 times. There is no particular upperlimit to the number of times, but from a viewpoint of cost, it is, forexample, equal to or less than 15 times, specifically equal to or lessthan 10 times.

A specific condition for the classification is only guideline, but thecondition of the classification is preferably set so that a fine powderhaving a particle size equal to or less than 10 μm is removed, and thecondition of the classification is more preferably set so that a finepowder having a particle size equal to or less than 7.5 μm is removed.In a case of the sedimentation classification, Stokes' equation for asedimentation velocity of particles can be referred to for setting thecondition.

For an example of specific condition for sedimentation classification,the examples which will be described later can be referred to.

<Light-Emitting Device, Image Display Device, and Illumination Device>

A light-emitting device can be obtained by combining the phosphor powderof the present embodiment and a light emitting source.

The light emitting source typically emits ultraviolet or visible light.For example, in a case where the light emitting source is a blue LED,the blue light emitted from the light emitting source hits the phosphorpowder and the blue light is converted into light having a longerwavelength. That is, the phosphor powder of the present embodiment canbe used as a wavelength conversion material that converts the blue lightinto light having a longer wavelength.

An example of a specific configuration of the light-emitting device willbe described with reference to FIG. 1 .

FIG. 1 is a schematic cross-sectional view showing an example of astructure of a light-emitting device. As shown in FIG. 1 , alight-emitting device 100 includes a light-emitting element 120, a heatsink 130, a case 140, a first lead frame 150, a second lead frame 160, abonding wire 170, a bonding wire 172, and a composite 40.

The light-emitting element 120 is mounted in a predetermined region onthe upper surface of the heat sink 130. By mounting the light-emittingelement 120 on the heat sink 130, the heat dissipation of thelight-emitting element 120 can be enhanced. Further, a packagingsubstrate may be used instead of the heat sink 130.

The light-emitting element 120 is a semiconductor element that emitsexcitation light. As the light-emitting element 120, for example, an LEDchip that generates light at a wavelength of equal to or more than 300nm and equal to or less than 500 nm, corresponding to near-ultravioletto blue light, can be used. One electrode (not shown in the drawings)arranged on the upper surface side of the light-emitting element 120 isconnected to the surface of the first lead frame 150 through the bondingwire 170 such as a gold wire. In addition, the other electrode (notshown in the drawings) formed on the upper surface of the light-emittingelement 120 is connected to the surface of the second lead frame 160through the bonding wire 172 such as a gold wire.

In the case 140, a substantially funnel-shaped recess whose holediameter gradually increases toward the upside from the bottom surfaceis formed. The light-emitting element 120 is provided on the bottomsurface of the recess. The wall surface of the recess surrounding thelight-emitting element 120 serves as a reflective plate.

The recess whose wall surface is formed by the case 140 is filled withthe composite 40. The composite 40 is a wavelength conversion memberthat converts excitation light emitted from the light-emitting element120 into light at a longer wavelength.

The composite 40 is obtained by dispersing at least the phosphor powderof the present embodiment in the sealing material 30 such as resin. Inorder to obtain white light of higher quality, the sealing material 30may contain not only the phosphor powder of the present embodiment butalso other phosphor powders.

The light-emitting device 100 emits a mixed color of light from thelight-emitting element 120 and light emitted from the phosphor particles1 excited by absorbing the light emitted from the light-emitting element120. The light-emitting device 100 preferably emits white light bymixing the light from the light-emitting element 120 and the lightgenerated from the phosphor particles 1.

Incidentally, FIG. 1 illustrates a surface-mounted type light-emittingdevice, but the light-emitting device is not limited to thesurface-mounted type, and may be shell-type, chip-on-board (COB) type,or chip-scale package (CSP) type.

The light-emitting device is used in an image display device such as adisplay and an illumination device. For example, a liquid crystaldisplay can be manufactured using the light-emitting device 100 as abacklight. In addition, the illumination device can be manufactured byperforming suitable wiring using one or a plurality of thelight-emitting devices 100.

The embodiments of the present invention have been described above, butthese are examples of the present invention and various configurationsother than the examples can also be adopted. In addition, the presentinvention is not limited to the above-described embodiment, andmodifications, improvements, and the like within the range in which theobject of the present invention can be achieved are included in thepresent invention.

EXAMPLES

The embodiment of the present invention will be described in detailbased on examples and comparative examples. It is noted, just to besure, that the present invention is not limited to only Examples.

Producing Phosphor Powder Example 1

(1) Preparation of Raw Material Mixed Powder

First, premixing was performed. Specifically, among the raw materialsshown in Table 1, Si₃N₄, AlN, and CeO₂ were mixed (dry-blended) for 30minutes using a small V-type mixer, and then sieved with a nylon sievehaving an opening of 150 μm. A premixed powder was thus obtained.

Next, in a glove box of the nitrogen atmosphere, the remaining materials(Ca₃N₂ and Li₃N) of the raw materials shown in Table 1 were added to thepremixed powder, thoroughly dry-blended, and then sieved with a sievehaving an opening of 500 μm. A raw material mixed powder was thusobtained.

(2) Firing

A container formed of boron nitride was filled with the raw materialmixed powder. This container was placed in a furnace, and the rawmaterial mixed powder was fired at 1800° C. for 8 hours in a N₂atmosphere of 0.72 MPa·G.

(3) Pulverization of Fired Product

The fired product obtained in (2) was pulverized using a stamp mill. Thepulverization by the stamp mill was repeated until a passing rate of avibrating sieve having an opening of 250 μm exceeded 90%.

The fired product pulverized by the stamp mill was further pulverized byusing a jet mill (manufactured by Nippon Pneumatic Mfg, PJM-80SP). Inpulverization conditions, a sample supply rate was set as 50 g/min and apulverization air pressure was set as 0.3 MPa.

(4) Acid Treatment

The pulverized fired product was put into hydrochloric acid for acidtreatment.

Specifically, first, 35 to 37% by mass of hydrochloric acid anddistilled water were mixed at a volume ratio of 50 mL:300 mL to preparean aqueous solution of hydrochloric acid heated to 80° C. The firedproduct pulverized in (3) was added to this aqueous solution ofhydrochloric acid and stirred for 0.5 hours for the acid treatment.

The acid-treated fired product was thoroughly washed with distilledwater and then dried at 110° C. for 3 hours. Then, it was sieved with asieve having an opening of 45 μm to remove coarse/aggregated particles.

(5) Removal of Fine Powder by Sedimentation Classification

First, an aqueous solution of 0.05% by mass sodium hexametaphosphate wasprepared. Then, this aqueous solution was placed in a container havingan inner diameter of 70 mm and a height of 120 mm up to a height of 110mm.

Next, the acid-treated fired product was put into the containercontaining the above aqueous solution, thoroughly stirred and dispersed,and then allowed to stand still for 22 minutes. After standing still, asupernatant was discharged from the top by 90 mm. After that, theaqueous solution of sodium hexametaphosphate was added up to a height of110 mm, and the powder was dispersed by stirring again, and the sametreatment was performed. This operation was repeated 7 times to removethe fine powder contained in the acid-treated powder (incidentally, aclassification point is 7.5 μm based on the Stokes' equation).

Then, a slurry at the bottom of the container was filtered while washingwith water to collect a solid content, dried in a condition of 110° C.for 3 hours, and sieved with a sieve having an opening of 45 μm to crushaggregated particles.

From the above, the phosphor powder was obtained.

Example 2

A phosphor powder was obtained in the same manner as in Example 1,except that the sedimentation classification was not performed.

Comparative Example 1

A phosphor powder was obtained in the same manner as in Example 1,except that (a) a material shown in Table 1 was used as the rawmaterial, (b) the acid treatment was not performed, and (c) thesedimentation classification was not performed.

<Confirmation of Chemical Composition/Crystal Structure>

Some phosphor powders were analyzed for composition as follows.

Amounts of Ca, Li, Ce, Si, and Al: the phosphor powder was dissolved byan alkali fusion method, and then the amounts thereof were measured withan ICP emission spectrometer (CIROS-120 manufactured by Rigaku Co.,Ltd.).

Amount of 0 and N: measured with an oxygen nitrogen analyzer(manufactured by HORIBA, EMGA-920).

Based on the measurement results, x, y, the Si/Al atomic ratio, the O/Natomic ratio, the Li ratio of M, and the Ce ratio of M in the generalformula M_(x)(Si, Al)₂(N, O)_(3±y) were obtained.

In addition, the phosphor powder was dissolved with a mixed acid ofhydrofluoric acid and nitric acid by a pressure acid decompositionmethod, and then, the contents of the Cr element, the Fe element, the Nielement, and the Ti element were measured by an ICP emissionspectrometer.

The phosphor of Example 1 was also subjected to powder X-ray diffraction(XRD) measurement using Cu-Kα rays using an X-ray diffractometer (UltimaIV-N manufactured by Rigaku Co., Ltd.). The obtained XRD pattern isshown in FIG. 2 . From the analysis of the obtained XRD pattern,crystals with lattice constants of a=0.9486 nm, b=0.5586 nm, andc=0.4933 nm as orthorhombic crystal were confirmed as a main phase and asmall amount of LiAlSi₂N₄ was confirmed as the heterogeneous phase.

<Measurement of Particle Size Distribution>

The particle size distribution was measured by a laser diffractionscattering method based on JIS R 1629:1997 using LS13 320 (manufacturedby Beckman Coulter, Inc.). Water was used as a measurement solvent.

As a specific procedure, first, a small amount of phosphor powder wasadded to an aqueous solution containing 0.05% by mass of sodiumhexametaphosphate as a dispersant. Next, dispersion treatment wasperformed with a horn-type ultrasonic homogenizer (output of 300 W, horndiameter of 26 mm) to prepare a dispersion. The particle sizedistribution was measured using this dispersion. A 10% volume size D₁₀,a 50% volume size D₅₀, and a 90% volume size D₉₀ were obtained from theobtained cumulative volume frequency distribution curve.

<Evaluation>

(Fluorescence peak intensity)

A fluorescence spectrum of the phosphor powder was measured using aspectro fluorophotometer (F-7000, manufactured by Hitachi High-TechScience Co., Ltd.) corrected with Rhodamine B and a secondary standardlight source. Specifically, the fluorescence spectrum emitted byexciting the phosphor powder with monochromatic light having awavelength of 455 nm was measured, and the fluorescence peak intensityand fluorescence peak wavelength were determined.

The fluorescence peak intensity varies depending on the measuring deviceand conditions. The fluorescence peak intensity described in the tablebelow is a value in a case where the fluorescence peak intensity of astandard sample (YAG, more specifically P46Y3 manufactured by MitsubishiChemical Corporation) is set to 100.

(Internal Quantum Efficiency and External Quantum Efficiency)

Using a spectrophotometer (MCPD-7000 manufactured by Otsuka ElectronicsCo., Ltd.), internal quantum efficiency and external quantum efficiencyof each phosphor powder were obtained by the following procedure.

-   -   (1) The phosphor powder was filled into a recessed part of a        recessed cell to have a smooth surface. This recessed cell was        attached to a predetermined position (a sample part) within an        integrating sphere. Monochromatic light spectrally split into a        wavelength of 455 nm from a light emitting source (Xe lamp) was        introduced into the integrating sphere using an optical fiber.        This monochromatic light (excitation light) was emitted to the        phosphor powder filled in the recessed part of the recessed        cell, and the fluorescence spectrum was measured. From the        spectral data obtained, a peak wavelength was determined, and        the number of excitation reflected light photons (Qref) and the        number of fluorescence photons (Qem) were calculated. The number        of excitation reflected light photons was calculated in a        wavelength range of equal to or more than 450 nm and equal to or        less than 465 nm, and the number of fluorescence photons was        calculated in a wavelength range of equal to or more than 465 nm        and equal to or less than 800 nm.    -   (2) In addition, instead of the recessed cell, a standard        reflective plate (Spectralon manufactured by Labsphere, Inc.)        having a reflectance of 99% was attached to the sample part, and        a spectrum of the excitation light at a wavelength of 455 nm was        measured. Then, the number of excitation light photons (Qex) was        calculated from the spectrum in a wavelength range of equal to        or more than 450 nm and equal to or less than 465 nm.    -   (3) From the Qref, Qem, and Qex obtained in (1) and (2) above,        the internal quantum efficiency and the external quantum        efficiency were calculated based on the following equations.

Internal quantum efficiency=(Qem/(Qex−Qref))×100

External quantum efficiency=(Qem/Qex)×100

Various pieces of information are collectively shown in Table 1.

In Table 1, “N.D.” stands for Not Detected.

In addition, in Table 1, each raw material described in a column of “rawmaterials used” is as follows.

-   -   Ca₃N₂-1: Ca₃N₂ manufactured by Taiheiyo Cement Co., Ltd.    -   Ca₃N₂-2: Ca₃N₂ manufactured by CERAC, Inc. (currently Materion,        Co.)

Li₃N-1: Li₃N from Materion, Corp.

Li₃N-2: Li₃N manufactured by CERAC, Inc. (currently Materion, Corp.)

CeO₂-1: CeO₂, C grade manufactured by Shin-Etsu Chemical Co., Ltd.

Si₃N₄-1: Si₃N₄ manufactured by Ube Industries Ltd., E10 grade

AlN-1: AlN manufactured by Tokuyama Corporation, E grade

TABLE 1 Example/Comparative Example Comparative Example 1 Example 2Example 1 Raw material Ca₃N₂ 19.528 19.528 19.528 (% by mass) Li₃N 3.9003.900 3.900 CeO₂ 3.345 3.345 3.345 Si₃N₄ 55.437 55.437 55.437 AlN 17.79117.791 17.791 Raw material Ca₃N₂ Ca₃N₂-1 Ca₃N₂-1 Ca₃N₂-2 used Li₃NLi₃N-1 Li₃N-1 Li₃N-2 CeO₂ CeO₂-1 CeO₂-1 CeO₂-1 Si₃N₄ Si₃N₄-1 Si₃N₄-1Si₃N₄-1 AlN AlN-1 AlN-1 AlN-1 Chemical x 0.78 0.76 0.84 composition y0.33 0.34 0.34 Si/Al 2.49 2.46 2.72 O/N 0.04 0.05 0.05 Li/M 32.39 30.4340.45 (mol %) Ce/M 2.87 3.02 2.73 (mol %) Impurities Cr N. D. N.D. 3.1(ppm) Fe 6.6 7.3 17.4 Ni N.D. N.D. Unmeasured Cr + Fe + Ni 6.6 7.3 >20.5Ti N.D. N.D. Unmeasured Particle size D₁₀ (μm) 9.9 6.0 6.4 distributionD₅₀ (μm) 16.2 14.7 13.9 D₉₀ (μm) 25.0 24.5 23.0 Fluorescence peak 595.8600.3 595.3 wavelength (nm) Production method Including Including Notincluding hydrochloric acid hydrochloric acid hydrochloric acidtreatment and treatment and treatment and sedimentation not includingsedimentation classification sedimentation classification classificationRelative fluorescence 126.3 118.6 100.9 peak intensity (455 nm, P46Y3ratio) Internal quantum efficiency 80.9% 80.0% 71.9% External quantumefficiency 70.9% 65.8% 62.6%

The phosphor powders of Examples 1 and 2 had a lower total content ofCr+Fe+Ni than Comparative Example 1, and exhibited excellentfluorescence peak intensity, internal quantum efficiency, and externalquantum efficiency.

This application claims priority based on Japanese Patent ApplicationNo. 2020-202770 filed on Dec. 7, 2020, the disclosure of which isincorporated herein by reference in its entirety.

REFERENCE SIGNS LIST

-   -   1 phosphor particles    -   30 sealing material    -   40 composite    -   100 light-emitting device    -   120 light-emitting element    -   130 heat sink    -   140 case    -   150 first lead frame    -   160 second lead frame    -   170 bonding wire    -   172 bonding wire

1. A phosphor powder including phosphor particles which are a phosphorrepresented by a general formula M_(x)(Si, Al)₂(N, O)_(3±y) (where M isLi and one or more alkaline earth metal elements and 0.52≤x≤0.9 and0.06≤y≤0.36 are satisfied) and in which a part of M is substituted witha Ce element, wherein a Si/Al atomic ratio is equal to or more than 1.5and equal to or less than 6, an O/N atomic ratio is equal to or morethan 0 and equal to or less than 0.1, 5 to 50 mol % of M is Li, and 0.5to 10 mol % of M is Ce, and a total content of a Cr element, a Feelement, and a Ni element in the phosphor powder is equal to or lessthan 20 ppm.
 2. The phosphor powder according to claim 1, wherein acontent of a Ti element in the phosphor powder is equal to or less than5 ppm.
 3. The phosphor powder according to claim 1, wherein a D₁₀ isequal to or more than 2 m and equal to or less than 15 m.
 4. Alight-emitting device comprising: the phosphor powder according to claim1; and a light emitting source.
 5. The light-emitting device accordingto claim 4, wherein the light emitting source emits ultraviolet light orvisible light.
 6. An image display device comprising: the light-emittingdevice according to claim
 4. 7. An illumination device comprising: thelight-emitting device according to claim 4.